Abstract:

A reverse molded, plant-on decorative panel component comprises a panel
portion lying on a first plane, a skirt portion, and a contoured portion.
The skirt portion has a first surface adapted to be exteriorly disposed
and an opposite second surface adapted to be interiorly disposed in order
to be adhesively secured to a planar surface. The contoured portion
extends outwardly from and surrounds the panel portion and interconnects
and is integral with the panel portion and the skirt portion. The skirt
portion extends peripherally about the contoured portion.

Claims:

1. A reverse molded, plant-on decorative panel component, comprising: a
panel portion lying on a first plane; a skirt portion having a first
surface adapted to be exteriorly disposed and an opposite second surface
adapted to be interiorly disposed in order to be adhesively secured to a
planar surface; and a contoured first portion extending outwardly from
and surrounding said panel portion and interconnecting and integral with
said panel portion and said skirt portion, said skirt portion extending
peripherally about said contoured portion.

2-9. (canceled)

10. A reverse molded wood composite door skin, comprising: at least one
panel portion lying on a first plane; a skirt portion having a first
surface adapted to be exteriorly disposed and an opposite second surface
adapted to be interiorly disposed in order to be adhesively secured to a
planar surface; and an outwardly extending contoured first portion
surrounding said panel portion and interconnecting and integral with said
panel portion and said skirt portion, said skirt portion extending
peripherally about said panel.

11-20. (canceled)

21. A method of decorating a wood composite door, comprising the steps
of: providing a door having a planar door face; providing a reverse
molded wood composite door skin having a first surface adapted to be
exteriorly disposed and an opposite second surface adapted to be
adhesively secured to the door face, the door skin having at least one
panel portion lying on a first plane, a skirt portion, and a contoured
portion extending outwardly from and surrounding the panel portion and
interconnecting and integral with the panel portion and the skirt
portion, the skirt portion extending peripherally about the contoured
portion and being disposed angularly relative to the first plane; and
adhesively securing the door skin to the door face so that the skirt
portion is tensioned against the door face.

22-32. (canceled)

Description:

CLAIM TO PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. patent
application Ser. No. 09/761,394, filed Jan. 16, 2001, which is a
continuation-in-part of U.S. patent application Ser. No. 09/742,840,
filed December 21, 2000, which is based on U.S. Provisional Patent
Application Ser. No. 60/198,709 filed Apr. 20, 2000, the disclosures of
all of which are incorporated herein by reference.

[0003] The present invention is directed to a reverse molded, plant-on
decorative panel component. The plant-on component comprises a panel
portion lying on a first plane, a contoured portion, and a skirt portion.
The plant-on component has a first surface adapted to be exteriorly
disposed and an opposite second surface adapted to be interiorly disposed
in order to be adhesively secured to a planar surface. The contoured
portion extends outwardly from and surrounds the panel portion, and
interconnects and is integral with the panel portion and the skirt
portion. The skirt portion extends peripherally about the contoured
portion, and may be disposed angularly relative to the first plane. The
present invention is also directed to a method of decorating a planar
surface, such as a door face, with the disclosed plant-on panel
component.

BACKGROUND OF THE INVENTION

[0004] Man-made boards, such as fiberboard, e.g., hardboard; chipboard;
oriented strand board-fiberboard composites; particle board; oriented
strand board-particle board composites; and the like, may be formed into
articles having contoured portions simulating stiles, rails, panels, or
other desired features. Generally, such articles are formed from a planar
cellulosic mat, and may include one or more interior depressions or
raised contours simulating panels or other decorative features. For
example, one method of manufacturing molded wood composite articles is
disclosed in U.S. Pat. No. 5,543,234 to Lynch et al, the disclosure of
which is incorporated herein by reference. Such molded articles commonly
are embossed downwardly on their intended visible major outer surface in
the manufacture of interior paneling, exterior siding, cabinet and
furniture doors, and door skins, such that the exterior surfaces, such as
stiles and rails, are the highest structure of the embossed product. The
formed depressions and contoured portions may replicate a natural wood
paneled door. Doors having such molded door skins are much less expensive
compared to a natural wood door.

[0005] The prior art discloses that it is difficult to reverse mold and to
emboss deep draws into a fiberboard panel due to stretching and breaking
of the fibers. A reverse molded fiberboard is stretched more on its
visible outer surface than on its interior surface (i.e. the surface in
contact with a raised mold surface) making reverse molding much more
difficult when attempting to provide sharp, crisp design detail in a
raised panel that simulates natural wood millwork.

[0007] The cellulosic fibers used to form the loose mat, e.g. a 1 inch to
2 inch, preferably a 11/2 or 13/4 inch, thick layer of cellulosic fibers
having a specific gravity of, for example, 0.6, initially may be bone dry
after the fibers have been dried and felted, but the cellulosic fibers in
such mats absorb moisture from the atmosphere and generally include about
2% to about 10% moisture when molded via hot pressing, depending upon the
humidity in the region where such mats are stored and/or manufactured.

[0008] The reverse molded panels of the present invention are particularly
suitable as wainscot panels. The panels are reverse molded to provide a
"profile up" configuration. The reverse molding approach permits mounting
the panel directly against a wall versus the prior art method requiring
"shim spacers" (see FIG. 6A), thereby promoting easy installation while
integrating excellent aesthetics of a wainscot panel. Historic treatments
of real wood wainscot are well established and very expensive. Beyond the
multiple piece millwork of real wood, some gypsum and polymeric materials
have been fabricated into wainscot panels, but are marginally
commercially acceptable, partly because they do not have the feel or look
of natural wood. There are no wood fiber composite reverse molded
wainscot systems available that provide the ease of application that is
achieved in accordance with the principles of the present invention.

[0009] With respect to conventional doors, molded door skins may be
adhesively secured to a wood frame support structure to produce a
finished door. Rails and stiles may also be used to provide additional
structural support for the door. Such doors are well known in the art,
and provide consumers with an aesthetically appealing, yet cost efficient
alternative to traditional, solid wood doors.

[0010] A consumer may desire to replace an existing flat or flush door
with a door having a contoured exterior surface. For example, a consumer
may completely replace a door having a planar surface with a door having
contoured molded door skins. However, this requires that the existing
door be completely replaced. Often, the existing doorframe, door hinges
and lock mechanism must also be replaced or modified, given the new
replacement door may have different dimensions from the existing door.
Similarly, if a consumer wants to replace a cabinet door or paneling, the
pre-existing cabinet door or paneling must be completely replaced. Again,
the new molded door or paneling may not have the proper dimensions for
simple replacement. As such, structural modifications must be made, or
the entire existing article must be replaced. For example, the dimensions
of kitchen cabinets may be such that replacement of only the cabinet door
is not possible. Thus, the entire cabinet may need to be replaced. Such
complete replacement is often expensive, and can be cost prohibitive for
many consumers.

[0011] Various attempts to provide consumers with a cost efficient
alternative to complete replacement of a planar door or other article
have been made. In one such attempt, a molded plastic panel is provided,
which is adhesively secured to a face of a conventional flat plywood
door. Such plastic panels generally include an interior planar portion,
surrounded by a contoured portion. The interior portion of the panel is
secured to the door face. Often, a gap or parting tine is created between
the outer perimeter of the contoured portion and the door face, which is
aesthetically unacceptable for many consumers.

[0012] In an attempt to minimize the gap between the panel and door face,
a bead of caulk is often required to eliminate the gap. However, this may
not present a satisfactory appearance. The caulk often dries and cracks
over time, and therefore must be maintained and/or replaced periodically.
In addition, the caulk may not match the color of the door face and/or
panel. Furthermore, the caulk usually has a different texture and surface
appearance compared to the plastic panel and the plywood door face.
Therefore, even if the panel and door are painted, the surface appearance
is often unsatisfactory for many consumers. Thus, such panels do not
provide an acceptable alternative for many consumers.

[0013] Other attempts to provide an acceptable alternative to complete
replacement provide for wood composite panels or skins that may be
secured to a planar surface, such as a molded wood composite door skin or
wainscot paneling. Although such wood composite articles provide some
advantages over plastic molded panels, all of the above noted problems
with plastic panels are not overcome. Specifically, the outer perimeter
of molded wood composite panels may develop a gap or parting line with
the contact surface. The wood composite article and/or the planar contact
surface (such as a planar door face) may warp or sag over time, thereby
creating a parting line. Adhesively securing such panels may provide an
adequate adhering force for retaining the panel to the planar surface
generally, but there is no tensioning force maintaining the outer
perimeter of the panel to the planar surface. Thus, a parting line often
develops.

[0014] Therefore, there is a need for a molded panel component that may be
secured to an existing planar surface, which has an aesthetically
acceptable appearance for consumers. There is also a need for a molded
panel component that is tensioned to the planar surface, which maintains
an adhering force tensioning the panel component to the planar surface.

SUMMARY OF THE INVENTION

[0015] The present invention is directed to a reverse molded fiberboard
panel; a wainscot kit comprising a plurality of differently sized reverse
molded panels, and a planar finishing or spacer panel, adapted to
completely cover any size wall between a wall base board and a wall chair
rail; and a method of reverse molding a loose cellulosic mat, in a single
pressing step, to provide one or more relatively high density, raised
panels without requiring preliminary pressing, or other pre-shaping step,
such as scalping. The reverse-molded panels are molded in a conventional,
multi-opening fiberboard press, in a single pressing step process, while
achieving excellent transfer of mold detail (embossing fidelity) without
visually noticeable fiber fracture. The panels can include a foil, an
impregnated paper overlay, or thermoplastic coating materials but do not
require an overlay or high resin content coating to achieve excellent
embossing fidelity and appearance.

[0016] In one embodiment, the loose cellulosic mat that is molded is
manufactured by the dry process to provide a smooth, planar back surface
surrounding the back surface of the raised, molded panels, rather than a
screen back pattern which results from pressed mats made by the wet
process. The reverse molded raised panel design provides a raised profile
(profile up) that is sharp and crisp with sharp detail in exterior
corners that has the appearance and feel of hand crafted natural wood
millwork, but actually is a reverse-molded, high density wood composite
material that can be adhesively secured to a planar wall, such as gypsum
wallboard.

[0017] Accordingly, one aspect of the present invention is to provide
reverse molded, wood composite articles, and a method of manufacturing
the articles, wherein the articles are molded from a loose mat of
cellulosic fiber and binder, such that the articles have an upwardly
raised panel that simulates natural wood millwork.

[0018] Another aspect of the present invention is to provide reverse
molded, wood composite articles, and a method of manufacturing the
articles, in kit form, such that the articles can be securely adhered to
any planar surface, such as a gypsum wallboard, or plaster wall, to fill
the entire wall area between a base board and a chair rail, while
providing sharp, crisp exterior corners on the reverse molded, raised
panel, to simulate-natural wood, handcrafted millwork.

[0019] Another aspect of the present invention is to provide a wainscot
kit comprising a plurality of reverse molded wood composite articles
having different widths and a planar panel that can be easily cut to a
desired width to fill an entire wall between a base board and a chair
rail.

[0020] Still another aspect of the present invention is to provide a
reverse molded wood composite article that provides exact transferring of
mold detail at exterior corners and contours in a single pressing
operation without requiring multiple press steps, post mold curing at
elevated temperatures, or a foil or a high resin content (5-25%) outer
surface portion.

[0021] Another aspect of the present invention is to provide reverse
molded wood composite articles that can be molded from cellulosic mats
that do not require synthetic fibers, scrim surfaces, layering of short
and long fibers, resin-impregnated paper overlays, thermoplastic
varnishes, or needling (needle punching) to hold the mat together prior
to molding.

[0022] A further aspect of the present invention is to provide a reverse
molded wood composite article that has one or more raised panels
including a centrally disposed rectangular panel portion of 5-10 mm in
height, surrounded by a raised, molded, contoured millwork design having
a plurality of raised, planar steps ascending upwardly and inwardly
integral with rounded contours to a rounded top portion that has
increased density at a rounded apex, to prevent damage and surface fiber
fractures, and has a geometry such that sharp, crisp surface detail is
provided, particularly at exterior corners of the millwork geometry, in a
single pressing (molding) step, while providing substantially uniform
density in all but the rounded apex of the raised, molded rectangular
millwork design.

[0023] Another aspect of the present invention is to provide a reverse
molded wood composite article that can be molded in a strip of multiple
parts in a single pressing (molding) operation and can be cut into
separate parts after molding and then coated with a water-based and/or
solvent-based coating material, e.g., paint or stain.

[0024] Still another aspect of the present invention is to provide a
wainscot kit that includes a plurality of reverse molded wood composite
articles to provide at least two differing raised panel (window) sizes,
at least two different composite article widths, wherein a smaller width
composite article has a proportionately smaller raised panel width, and a
planar spacer panel, so that the combination of composite articles can
completely fill a wall between a base board and a chair rail by cutting
the planar spacer panel to size at inside wall corners for covering the
full wall width up to the chair rail. More particularly, the preferred
reverse molded articles in the kit are provided in widths of 12 inches,
16 inches and 48 inches with the 12 inch and 16 inch widths having
windows (raised panels) of different sizes; and the 48 inch wide article
having three windows of a size to match either the 12 inch wide or 16
inch wide article.

[0025] Another aspect of the present invention is to provide a reverse
molded wood composite article that has one or more raised panels
comprising a central, planar raised portion surrounded by a rectangular
raised millwork design, the raised panels being, surrounded by planar
stiles and rails wherein the raised panels are capable of being separated
from the surrounding planar stiles and rails, e.g., via sawing or back
sanding, from the surrounding planar base so that the separated panels
can be adhered to a household door, cabinet door, shutters, furniture,
library or millwork walls, or as a framing material by further removing
the central planar raised panel portion.

[0026] In a second embodiment of the present invention, a reverse molded,
plant-on decorative panel component is provided. The panel component
includes a panel portion lying on a first plane, a skirt portion having a
first surface adapted to be exteriorly disposed and an opposite second
surface adapted to be interiorly disposed in order to be adhesively
secured to a planar surface, and a contoured first portion extending
outwardly from and surrounding the panel portion and interconnecting and
integral with the panel portion and the skirt portion. The skirt portion
extends peripherally about the contoured first portion, and may be
angularly disposed relative to the first plane.

[0027] The present invention also relates to a reverse molded wood
composite door skin. The door skin comprises at least one panel portion
lying on a first plane, a skirt portion having a first surface adapted to
be exteriorly disposed and an opposite second surface adapted to be
interiorly disposed in order to be adhesively secured to a planar
surface, and an outwardly extending contoured first portion surrounding
the panel portion and interconnecting and integral with the panel portion
and the skirt portion. The skirt portion extends peripherally about the
panel portion, and may be disposed angularly relative to the first plane.

[0028] A method of decorating a planar surface of a door comprises the
steps of: providing a door having a planar door face; providing a
plant-on panel component, the panel component comprising a panel portion
lying on a first plane, a skirt portion having a first surface adapted to
be exteriorly disposed and an opposite second surface adapted to be
interiorly disposed in order to be adhesively secured to the door face,
and a contoured portion extending outwardly from and surrounding the
panel portion and interconnecting and integral with the panel portion and
the skirt portion, the skirt portion extending peripherally about the
contoured portion and being disposed angularly relative to the first
plane; and adhesively securing the plant-on decorative panel component to
the planar door face so that the skirt portion is tensioned against the
door face.

[0029] A method of decorating a wood composite door, comprising the steps
of: providing a door having a planar door face; providing a reverse
molded wood composite door skin having a first surface adapted to be
exteriorly disposed and an opposite second surface adapted to be
adhesively secured to the door face, the door skin having at least one
panel portion lying on a first plane, a skirt portion, and a contoured
portion extending outwardly from and surrounding the panel portion and
interconnecting and integral with the panel portion and the skirt
portion, the skirt portion extending peripherally about the contoured
portion and being disposed angularly relative to the first plane; and
adhesively securing the door skin to the door face so that the skirt
portion is tensioned against the door face.

[0030] A kit for decorating a planar surface comprises at least a first
reverse molded wood element. The element comprises at least one panel
portion lying on a first plane, a skirt portion having a first surface
adapted to be exteriorly disposed and an opposite second surface adapted
to be interiorly disposed in order to be adhesively secured to a planar
surface. An outwardly extending contoured first portion surrounds the
panel portion and interconnects and is integral with the panel portion
and the skirt portion. The skirt portion extends peripherally about the
panel portion, and may be disposed angularly relative to the first plane.

[0031] A method of making a kit for decorating a planar surface comprises
the following steps: providing a mold press having an upper mold die and
a lower mold die, wherein the upper die has a planar zone, a contoured
zone and angles zones, and the lower die has a planar zone, a contoured
zone and angles zones complementary to the zones of the upper die,
respectively; positioning a cellulosic mat between the upper and lower
dies; and compressing the cellulosic mat between the upper and lower dies
and heating the cellulosic mat to a temperature sufficient to form a door
skin having at least one panel portion lying on a first plane, a skirt
portion having a first surface adapted to be exteriorly disposed and an
opposite second surface adapted to be interiorly disposed in order to be
adhesively secured to a planar surface, and an outwardly extending
contoured portion surrounding the panel portion and interconnecting and
integral with the panel portion and the skirt portion, the skirt portion
extending peripherally about the panel portion and being disposed
angularly relative to the first plane.

BRIEF DESCRIPTION OF THE FIGURES

[0032] FIG. 1 is a perspective view of upper and lower mold dies according
to a first embodiment of the present invention, and a wood fiber mat
disposed therebetween;

[0033] FIG. 2 is a fragmentary perspective view of the reverse molded
wainscot article according to the present invention;

[0034] FIG. 3 is an elevational view of components of a wainscot kit
including reverse molded panels;

[0035] FIG. 4 is a fragmentary elevational view of a wainscot kit having
reverse molded panels in one configuration around a window;

[0036] FIG. 5 is a fragmentary cross-sectional view of a reverse molded
wainscot article showing the profile of the reverse-molded raised panel;

[0037] FIG. 6 is a cross-sectional view of the reverse molded wainscot
article of FIG. 7 viewed along line 6-6 in the direction of the arrows;

[0038] FIG. 6A is a cross-sectional view of a prior art wainscot article
secured to a wall with shim spacers;

[0039] FIG. 7 is an elevational view of a wood composite wainscot article
having a switch plate for securing to a wall through the wainscot
article;

[0040] FIG. 8 is an elevational view of a plant-on decorative panel
component according to a second embodiment of the present invention;

[0041] FIG. 9 is a cross-sectional view of the panel component of FIG. 8
viewed along line 9-9 in the direction of the arrows;

[0042] FIG. 10 is a cross-sectional view of the panel component of FIG. 8
viewed along line 9-9 in the direction of the arrows after the panel
component has been adhered to a planar surface;

[0043] FIG. 11 is a perspective view of upper and lower mold dies
according to the second embodiment, and a wood fiber mat disposed
therebetween;

[0044] FIG. 12 is an elevational view of a molded door skin component
according to the present invention;

[0045] FIG. 13 is a cross-sectional view of the door skin component of
FIG. 12 viewed along line 13-13 in the direction of the arrows;

[0046] FIG. 14 is a fragmentary cross-sectional view of a panel component
according to another embodiment;

[0047] FIG. 15 is a fragmentary cross-sectional view of the panel
component of FIG. 14 prior to trimming and cutting the skirt portion of
the panel component; and

[0048] FIG. 16 is a perspective view of a door with plant-on elements from
a kit secured thereto.

DETAILED DESCRIPTION OF THE INVENTION

[0049] The present invention is directed to a reverse molded (profile up,
as molded) wood composite article particularly useful for the manufacture
of a wainscot panel or door facing surface, and to a method of making the
reverse molded wood composite article, having an upwardly inclined
profile molded upwardly from a planar base portion of the article. The
molded wood composite article of the present invention is preferably made
from a cellulosic mat containing a combination of cellulosic fibers,
including at least about 40% by weight, preferably at least about 60%,
softwood fibers, (from trees that produce cones) such as all species of
pine, and fir, e.g., Southern Pine, based on the total dry fiber weight,
and a natural or synthetic binder, such as a phenol formaldehyde or urea
formaldehyde resin. The cellulosic mat includes at least about 80%
refined, fibrillated cellulosic fibers, e.g., a fiberboard mat, such as
that hot-pressed to produce hardboard. The upper surface of the molded
article has excellent molding die fidelity and may have a smooth finish
or may be embossed to simulate a hardwood grain pattern, such as oak,
simulating furniture grade natural wood. The articles are molded from a
planar layer or mat of cellulosic fibers, e.g., a fiberboard mat, made
either by the wet process or the dry process, preferably the dry process.

[0050] Preferably, the fiberboard mat is one to three inches in thickness
before molding, and after molding is 1/8 to 1/4 inch in thickness having
co-planar stiles and rails, and planar back surfaces surrounding the
molded panels, such that the co-planar back surfaces are adapted for
flush contact against a wall or door surface, particularly between a wall
base board and chair rail, as a wainscot outer wall surface lining for an
interior household wall. The disclosed reverse molded panels may also be
manufactured in a kit, including a plurality of differently sized panels
adapted to completely line an interior wall, regardless of wall
dimension.

[0051] In a first embodiment of the present invention, molded wood
composite articles are molded in the form of wainscot paneling to be
adhered to a planar interior wall between a wall base board and a wall
chair rail, to simulate solid, natural wood wainscot millwork, as shown
in FIG. 2. It should be understood, however, that the principles of the
present invention are applicable to other molded articles, such as
exterior and interior doors or door skins, cabinet and furniture door
facings, furniture components, garage door skins, decorative wall
paneling, wardrobe door facings, decorative hardboard, and other such
molded, wood composite articles having one or more reverse-molded raised
millwork designs adjacent to a planar surface portion of the molded
article.

[0052] The dimensions of the reverse molded composite articles of the
first embodiment preferably varies from 5 inches to 96 inches in width
and from 12 inches to 60 inches or even 96 inches in height. Preferably,
the articles of the present invention are formed from at least 80% by
weight fibrillated cellulosic fibers, based on the total, dry weight of
fibers in the articles, and a binder capable of adhering the cellulosic
fibers together into a structurally stable, consolidated article. The
cellulosic fibers are in the form of refined, fibrillated fibers and can
be molded and adhered together with natural or synthetic binders to
provide aesthetically pleasing molded contours, and smooth or wood grain
texture surfaces in all exterior, visible surfaces, including the molded,
raised panel surfaces. The articles of the present invention can be
molded as a thin, e.g., 0.1 to 0.3 inch wainscot, or raised panels can be
cut or back sanded to remove the raised panels for adherence to a cabinet
door or the like to provide a raised, hand-crafted, natural wood millwork
look onto any planar surface. The reverse molded articles may then be
adhesively applied or otherwise fastened to any planar support structure.

[0053] Turning now to the drawings, and initially to FIG. 1, there is
illustrated a perspective view of a mold set, including a lower mold half
or mold cavity 4, having a partially broken-away cellulosic mat 5 laid
thereover, and an upper mold core 6, for pressing the mat 5 into a
wainscot panel, generally designated by reference numeral 10. The upper
mold core 6 has a mold depression 7 in its undersurface that is shaped
complementary to the upwardly extending mold design shown in lower mold
cavity 4 for pressing the mat 5 therebetween to conform to a mold cavity
between the mold halves 4 and 6. The wainscot panel 10 is reverse molded,
as shown in FIGS. 1 and 2, between the raised panel simulating lower mold
cavity 4, and the upper mold core 6, to provide raised panels 12 in the
molded article 10, including centrally disposed, planar raised panel
portions 13, and rectangular contoured wall portions, generally
designated by reference numeral 14, including raised exterior corners 15
on the panel outer surfaces that correspond to contours essentially
identical to raised contours of the lower mold cavity 4.

[0054] The reverse molded panel 10 can be secured, e.g., adhesively, or
via fasteners, such as nails or screws, to a suitable planar surface,
such as a wainscot wall area of an interior room. The lower mold cavity 4
is essentially the same in general contour as an upper surface of the
wainscot panel 10, except that the lower mold cavity 4 would be slightly
smaller horizontally, in the raised panel dimensions, to allow for the
thickness of the molded cellulosic mat 5 that is molded to the upwardly
extending raised panel design shown in FIG. 2. The upper mold core 6
carries a raised panel-receiving mold cavity 7 dimensioned complementary
to the upper surface of the raised panel structure 12, and can be
smoothly contoured or can include downwardly extending structure (not
shown) to emboss simulated wood grain ticks that form a wood grain
pattern.

[0055] The wainscot panel 10 is molded with the mold cavity, disposed
between die halves 4 and 6, disposed in a generally horizontal
disposition so that the upper major surface will be described as
horizontal corresponding to its disposition during molding and it will be
recognized that the position of the molded article, in use, is usually
intended to be vertical, instead of horizontal, as in the case of
wainscot panel 10, as shown in FIGS. 2-7. The "raised profile up" molded
outer major surface of the wainscot panels 10 is disposed in a vertical
orientation ("raised profile out") between a wall base board 16 and a
wall chair rail 18, as shown in FIG. 6.

[0056] Wainscot panel 10, shown in FIG. 2, preferably includes one or more
of the raised panels 12, which are molded to provide contoured walls 14
integral with and surrounding the centrally disposed planar raised panel
portion 13. The contoured walls 14 are also integral with and surrounded
by planar vertical stiles 20 and 22 and horizontal rails 24 and 26,
respectively, lying in a common plane, for adhesive securement of an
undersurface of each stile and rail 20, 22, 24 and 26 to a planar wall,
as shown in FIGS. 3 and 6.

[0057] In the preferred wainscot panel 10, best shown in FIGS. 2-4, the
reverse molded contoured walls 14 are molded in a rectangular shape,
surrounding the centrally disposed planar panel portion 13, and the
contoured walls 14 are interconnected to outer edges 27 of the planar
panel portion 13 through sloping walls 28, disposed therebetween. As best
shown in the panel profiles of FIGS. 5 and 6, the contoured walls 14
include a wall portion 30 that is integral with and extends upwardly from
an adjacent stile or rail (24, as shown in FIG. 5) at an angle of about
25° to about 35° above horizontal (as molded in the
horizontal position). Wall portion 30 then is curved downwardly in a
generally U-shaped contoured wall portion 32 integral at its outer end
with wall portion 30, and integral at its inner end with the planar,
raised panel portion 13, at outer edges 27 (FIGS. 2 and 5) of the planar,
raised panel portion 13. Each of the four contoured walls 14 that form
the reverse molded rectangles of each raised panel 12 are of identical
contour. In accordance with the preferred embodiment, U-shaped contoured
wall portion 32 is contoured such that an innermost undersurface 34 (as
applied against a wall) of the contoured wall portion 32, at the base of
the U, lies in the same plane as an undersurface 36 of the stiles and
rails 20, 22, 24 and 26, so that the undersurface 34 of U-shaped wall
portion 32, at the base of the U, contacts, and can be adhered to, wall
37 for structural support when in position (as shown in FIG. 6).

[0058] Preferably, the articles of the present invention are molded from a
loose mat of cellulosic fibers and a thermosetting binder, such as a urea
formaldehyde, melamine formaldehyde, and/or phenol formaldehyde binder
commonly used in the manufacture of fiberboard. The mat should include at
least about 80% fibrillated, refined cellulosic fibers, preferably 100%,
based on the total, dry fiber weight in the mat 5. The fibers are
mechanically refined from wood chips preferably using steam pressures in
the range of about 80 to 120 psi, more preferably about 100 to 110 psi,
most preferably about 105 psi. Steam pressures higher than about 120 psi
in refining the cellulosic 20 fibers produce highly refined fibers that
are useful in accordance with the present invention, but the cost of
refining would be commercially prohibitive.

[0059] Such refining of cellulosic fibers will provide fibrillated
cellulosic fibers that are preferably dry laid into a loose cellulosic
fiber mat having a basis weight in the range of 0.58 to 0.62 pounds per
cubic inch. Upon molding in a heated press at a temperature in the range
of about 385° F. to 450° F., and at a maximum pressure in
the range of about 550 to about 850 psi, the resulting embossed articles
will have a specific gravity in the range of about 0.96 to about 1.08,
preferably about 0.98 to about 1.06, more preferably about 1.00 to about
1.04. Articles of the present invention that are "profile up" compensate
to increase density and surface toughness by reducing caliper at the
highest point in the design profile to about 1.02 to about 1.08 specific
gravity, with a target of 1.02 to 1.04 specific gravity, whether smooth
or textured. The flat surface geometry surrounding the profile zones is
pressed to a slightly lower specific gravity of 1.00 to 0.98 by slightly
increasing the caliper within these zones.

[0060] The reverse molded panels 10 of the present invention can be
produced in a plurality of widths, as shown in FIG. 3. For example, a
molded panel 10A may be formed to have a width of 48 inches, with three
raised panels 12. A panel 10B may be formed to have a width of 16 inches,
with a single raised panel 12. A panel 10C may be formed to have a width
of 12 inches, also with a single raised panel 12. A planar panel 10D may
be formed having a width of 8 inches, which may then be easily cut
lengthwise to complete a wall. Panels 10A, 10B, 10C and 10D are
preferably the same height, for example 32 inches, which is a standard
wainscot height. As shown in FIG. 4, panels 10A-10D may be arranged under
and around a window 40. For example, panel 10B may be rotated 90°
(relative to the panel illustrated in FIG. 3) so that the raised panel 12
has its length in a horizontal disposition. If a window is lower to the
floor, panel 10C may also be used with either one or more planar panels
10D above and/or below panel 10C.

[0061] The wainscot kit shown in FIG. 3 may be easily installed by a
homeowner by starting at the center of the room, or directly under a
center window, and arranging the panels symmetrically toward inside
corners of the spaced wall ends. By arranging the panels 10B and/or 10C
properly, the 8 inch width planar panels 10D will be of sufficient width
to fill all walls, to the wall ends, defined at inside room corners, and
can be cut accurately to completely fill the wall.

[0062] In accordance with another aspect of the present invention,
electrical light switch plates (not shown) and outlet covers, generally
and collectively referred to by reference numeral 42 (FIG. 7), may be
provided with the kit of FIG. 3. These outlet covers 42 and switch plates
(not shown) are rectangular and have outermost vertical walls 44 that are
at least as high as the raised contoured walls 14 and planar raised panel
portions 13 of panels 12 so that wherever the light switch plates and/or
electrical outlet covers 42 are positioned within the wainscot panels 10,
a hole may be cut in the panels 12 to the same outer dimensions as the
switch plate cover or outlet cover 42, and the outlet cover 42 is
inserted against the wall (within the panel), without exposing a cut
panel, since the cuts in panel 12 will be flush against the outermost
walls 44 of the outlet cover 42, as shown in FIG. 7.

[0063] As best shown in FIG. 8, a second embodiment of the present
invention provides a reverse molded, plant-on decorative panel component
50, which may be adhesively secured to a planar surface, and is tensioned
to the planar surface when secured thereon. Plant-on panel component 50
comprises a panel portion 52 lying on a first plane, a skirt portion 54,
and a contoured portion 56. Preferably, panel portion 52 is rectangular.
However, it should be understood that panel portion 52 may be formed to
have any shape, pursuant to consumer preference. Panel portion 52 lies on
a plane that is coplanar with a plane extending between the uppermost
parts of contoured portion 56. Contoured portion 56 extends outwardly
from and surrounds panel portion 52 and interconnects and is integral
with panel portion 52 and skirt portion 54. Skirt portion 54 extends
peripherally about contoured portion 56.

[0064] As best shown in FIG. 9, which shows a cross-sectional view of
panel component 50 of FIG. 8 viewed along line 9-9 in the direction of
the arrows, skirt portion 54 is disposed angularly relative to the plane
of panel portion 52. Panel component 50 has a first surface 58 adapted to
be exteriorly disposed and an opposite second surface 60. Interior
surface 60a of skirt portion 54 is adapted to be adhesively secured to
the planar surface of a door, wall, building side, or the like. Skirt
portion 54 is angularly disposed inward, with respect to the plane of
exterior surface 58 of panel portion 52. Preferably, skirt portion 54 is
angled inwardly at least 5° from the plane of panel portion 52, as
best shown in FIG. 9 by arrow A. Arrow A subtends an angle of 185°
between the plane of panel portion 52 and skirt portion 54. However, it
should be understood that skirt portion 54 may also be angled inwardly
more than 5°, such as 10°, to provide additional tensioning
force between skirt portion 54 and the planar surface to which panel
component 50 is adhered. However, skirt portion 54 is preferably angled
inwardly from the plane of panel portion 52 a maximum of 15°,
because an angle of more than 15° may generate too much resistance
for skirt portion 54 to conform to a planar surface (discussed in detail
below). The tensioning force generated is also partially dependent on the
caliper or thickness of the panel component. Preferably, the panel
component has a finished caliper from between about 0.10 inches to about
0.25 inches.

[0065] FIG. 10 is a cross-sectional view of panel component 50 of FIG. 8
viewed along line 9-9 in the direction of the arrows after panel
component 50 has been adhered to a planar surface S. When panel component
50 is adhered to surface S, interior surface 60a of skirt portion 54 is
secured flush to surface S with an adhesive, such as double sided
adhesive tape, contact adhesive, hot-melt adhesive, and the like.
Therefore, when skirt portion 54 is forced onto surface S and adhered
thereto, the plane of skirt portion 54 is substantially parallel to the
plane of panel portion 52. Contoured portion 56 flexes to allow skirt
portion 54 to be so secured, thereby eliminating any perimeter gaps
occurring from a nonflat surface S where skirt portion 54 meets surface
S.

[0066] Contoured portion 56 is flexible enough to allow interior surface
60a of skirt portion 54 to be adhesively secured to surface S. When
interior surface 60a is secured flush against planar surface S, the
flexibility of contoured portion 56 and the angled disposition of
unsecured skirt portion 54 generate a tensioning force F between skirt
portion 54 and surface S, as shown by arrows F in FIG. 10. Similar to a
spring, skirt portion 54 is pushed onto surface S. This spring-like force
is generated due to the molded 5° angular configuration of skirt
portion 54 when in the natural or unsecured state, as best shown in FIG.
9. Even if panel component 50 and/or surface S warps, tensioning force F
will continue to push skirt portion 54 onto surface S, thereby
eliminating any gaps or parting lines that may otherwise develop. This
tensioning force F may or may not eliminate the angle of skirt portion
54, however any gaps are eliminated. Furthermore, it is not necessary to
caulk around panel component 50, since gaps do not develop.

[0067] As noted above, skirt portion 54 is formed to have an angular
configuration of at least 5°. The angle of skirt portion 54
relative to the plane of panel portion 52 should be formed so that a
sufficient tensioning force F is generated. A preferred angle range is
between about 5° to about 10° when the caliper of the panel
component is between about 0.10 inches to about 0.25 inches. A sufficient
tensioning force F maintains the spring-like adhering force that pushes
skirt portion 54 into surface S. From a visual standpoint, the angle
after adhering to surface S is insignificant. In addition, the angle of
skirt portion 54 should not be so great such that an excessive tensioning
force F is generated, which would cause the adhesive used to secure skirt
portion 54 to pull free from surface S. We have found that a 5°
angle configuration of skirt portion 54 provides an optimal tensioning
force F, without pulling panel component 50 free from surface S. However,
a greater angle may be formed depending on the strength of the adhesive
used, and the nature of the surface S to which panel component 50 is
adhered.

[0068] As in the first embodiment, panel component 50 is preferably molded
from a wood composite material, such as a loose mat of cellulosic fiber
and binder. Preferably the binder is present in an amount of about 3% to
about 4% by weight if panel component 50 is treated with linseed oil, and
about 6% to about 8% by weight resin when there is no linseed oil
treatment. The binder is preferably a thermosetting binder, such as
formaldehyde, melamine, formaldehyde, phenol formaldehyde, urea
formaldehyde, and methyl diisocyanate (MDI). Upon molding in a heated
press at a temperature in the range of about 385° F. to
450° F., and at a maximum pressure in the range of about 550 to
about 850 psi, molded panel component 50 will have a specific gravity in
the range of about 0.80 to about 1.10, preferably about 0.98 to about
1.06, more preferably about 1.00 to about 1.04.

[0069] As best shown in FIG. 11, mold press 62 includes an upper mold die
64 and a lower mold die 66. Mold press 62 forms a reverse molded panel
component 50, which has a "raised profile" that extends outwardly from
panel portion 52 relative to exterior surface 58, as best shown in FIGS.
9-10. The reverse molding process permits mounting panel component 50
directly against a planar surface S without using shims or spacers, as
best shown in FIG. 10. However, shims may be added as an option to
support panel portion 52 to provide resistance to high impact against the
panel. Mold press 62 may be a conventional, multi-opening fiberboard mold
press. Upper die 64 includes a planar zone 68, which corresponds to panel
portion 52, and contoured zones 70, which corresponds to contoured
portion 56. Upper die 64 also includes angled zones 72, corresponding to
the formation of skirt portion 54. Angled zones 72 extend downwardly from
upper die 64, preferably at an angle of at least about 5° relative
to planar zone 68. Lower die 66 has a configuration complementary to
upper die 64, including a planar zone 68a, contoured zones 70a, and
angled zones 72a.

[0070] Upper die 64 may also include a textured surface for embossing a
pattern on exterior surface 58 of panel component 50, such as a wood
grain pattern. Alternatively, a foil, impregnated paper overlay, or
thermoplastic coating may be compressed onto exterior surface 58 during
the compression process.

[0071] During the reverse molding process, upper and lower mold dies 64,
66 compress a wood fiber mat 5 into a desired configuration. As known in
the art, the cellulosic fibers comprising mat 5 do not "flow" when
compressed in mold press 62. Rather, the fibers are stretched,
particularly at points corresponding to contoured zones 70, 70a. This
stretching is maximized at points corresponding to exterior surface 58 of
contoured portion 56 during compression, resulting in fracturing and
fiber separation at such points due to the angle of force in reverse
molding, as well as the downward force of gravity during compression. By
contrast, interior surface 60 of contoured portion 56 maintains surface
integrity because the effects of stretching are not as severe, and
because the fibers are packed downward into the interior surface 60.
Specifically, the length of exterior surface 58 of contoured portion 56
is greater than the corresponding length of interior surface 60 of
contoured portion 56. As such, exterior surface 58 undergoes a greater
amount of stretching as compared to interior surface 60, particularly
with respect to contoured portion 56. Thus, the cellulosic fibers of mat
5 are stretched a greater distance on exterior surface 58, which often
results in fracturing of exterior surface 58 when conventional molding
methods are implemented.

[0072] Fracturing and fiber separation may be eliminated by adjusting
caliper at points where stretching is maximized (i.e. exterior surface 58
of contoured portion 56). During reverse molding, upper and lower mold
dies 64, 66 stretch and fracture the cellulosic fibers in cellulosic mat
5 at points corresponding to exterior surface 58 of contoured zones 70,
which is the intended visible surface. In order to mend and eliminate the
fractured areas on exterior surface 58, outwardly extending contoured
portion 56 is "pinched" in order to reduce caliper and achieve a desired
density. The reduced caliper creates a zone of overcompression of the
outwardly extending contoured portion 56, which re-mends any fractures on
exterior surface 58. In addition, the reduced caliper prevents
blistering, and achieves a hardened surface that is able to handle
additional abuse on or around the protruding, outwardly extending
contoured portion 56.

[0073] Thus, the stretching of cellulosic fibers during the compression of
mat 5 is most prevalent on exterior surface 58 of contoured portion 56,
which has a higher "length ratio". The length ratio is the ratio of an
exterior surface portion versus the corresponding interior surface
portion. Cellulosic fibers are stretched and pulled as the length ratio
increases, which results in decreased density and possibly surface
fracturing if caliper is not adjusted. It has been determined that an
increase in length ratio of between 15 and 75% is correlated to a
decrease in caliper by 12 to 28%. Thus, caliper adjustment of contoured
portion 56 is made as a means to effectively harden the surface at
contoured portion 56, thereby achieving excellent surface hardness and
paintability. Generally, caliper is reduced at the highest point in the
design profile to about 1.02 to about 1.08 specific gravity, with a
target of 1.02 to 1.04 specific gravity, whether smooth or textured. The
flat surface geometry surrounding contoured portion 56 (i.e. panel
portion 52 and skirt portion 54) is pressed to a slightly lower specific
gravity of 1.00 to 0.98 by slightly increasing the caliper within these
zones. Caliper adjustment for reverse molded panels is more fully
explained in WO 01/81055 to applicant Masonite Corporation, titled
Reverse Molded Panel, the disclosure of which is incorporated herein by
reference.

[0075] Panel component 50 may be formed in various sizes, as desired by
the consumer. For example, panel component 50 may vary from 5 inches to
96 inches in width, and from 12 inches to 60 inches in height. In
addition, panel portion 52 and skirt portion 54 may be formed to have
various dimensions. Preferably, skirt portion 54 is formed to have an
interior surface 60a with sufficient surface area for securely adhering
to surface S. Preferably, skirt portion 54 extends outwardly from
contoured portion 56 from between about 0.250 inches and about 0.375
inches. However, when panel component 50 is formed, skirt portion 54
extends from contoured portion 56 (i.e. the width of skirt portion 54)
much more than this preferred range. For example, skirt portion 54 may be
formed to have a width at least equal to the width of contoured portion
56, as best shown in FIGS. 8-10. Then, skirt portion 54 may be trimmed if
necessary, in order for panel component 50 to be easily modified by the
consumer and/or retail stores to fit a variety of planar surfaces S.
Therefore, it should be understood that skirt portion 54 may be any
desired width, so long as sufficient surface area on interior surface 60a
of skirt portion 54 is retained for adhesively securing to surface S.
Therefore, skirt portion 54 may be trimmed to have a width corresponding
to the width of a conventional bead of mastic, or adhesive tape.
Preferably, the width of skirt portion 54 is 0.5 inches or less. A skirt
portion 54 that is greater than 0.5 inches in width may have an adverse
affect on visual appearance of the panel component. Contoured portion 56
may also be formed in any desired configuration, so long as interior
surface 60 of contoured portion 56 does not extend below the plane of
interior surface 60a of skirt portion 54.

[0076] In a third embodiment of the present invention, a reverse molded
door skin component 80 is provided, as best shown in FIG. 12. Preferably,
door skin component 80 is formed from a wood composite material, as
described above for panel component 50. Door skin component 80 is similar
to panel component 50. Door skin component 80 may include more than one
panel portion, such as panel 82, 84, as shown in FIG. 12. Each panel
portion 82, 84 is surrounded by contoured portions 86, 88, respectively.
Panel portions 82, 84 may be any desired size and shape, and may have
identical or differing dimensions.

[0077] Skirt portions 90, 92 surround contoured portions 86, 88, as
described above for panel component 50, as best shown in FIG. 13. FIG. 13
is a cross-sectional view of door skin component 80 of FIG. 12 viewed
along line 13-13 in the direction of the arrows. Note that an
intermediate zone 94 is formed between and separating skirt portions 90
and 92. Intermediate zone 94 is parallel to panel portions 82, 84.
Intermediate zone 94 extends between skirt portions 90, 92, but has a
relatively small width, for example 0.187 inches or less. Preferably,
skirt portions 90, 92 each have a width of between about 0.250 inches to
about 0.375 inches. Skirt portions 90, 92 of door skin component 80 may
be trimmed to size along the perimeter of door skin component 80,
especially if the door surface on which door skin component 80 is to be
adhered is narrower in width than a standard size door. Because
intermediate zone has a width of only 0.187 inches, this flat
transitional zone is visually insignificant when door skin component 80
is adhered to the door surface given the slight 0.187 inches joining
skirt portions 90, 92.

[0078] Alternatively, door skin component 80 may be cut at intermediate
zone 94, forming two separate panel components. If cut at intermediate
zone 94, the slight 0.187 width of intermediate zone 94 again does not
impact the visual appearance. Note that although door skin component 80
is shown in FIGS. 12-13 to have two panel portions 82, 84, it is
understood that any number of panel portions may be formed in door skin
component 80 (with intermediate zones separating adjacent skirt
portions), thereby forming various designs and configurations for
consumers.

[0079] In a fourth embodiment of the present invention, a panel component
100 is provided having skirt portion 102 with a contoured exterior
surface 104 and a planar interior surface 106, as best shown in FIG. 14.
FIG. 14 is a fragmentary cross-sectional view of a panel component
according to the fourth embodiment. In addition to trimming. the length
of skirt portion 102, interior surface 106 of skirt portion 102 is sanded
or machined to provide a planar surface for adhering to surface S. FIG.
15 is a fragmentary cross-sectional view of panel component 100 of FIG.
14 prior to trimming and sanding an excess portion 107 from skirt portion
102. Unfinished skirt portion 102 is trimmed to cut line 200, so that
skirt portion 102 terminates in a rounded, radiused or arcuate end 105 at
its perimeter, and excess portion 107 is separated. Interior surface 106
is then sanded or trimmed along sand line 300, so that interior surface
106 is planar, as shown in FIG. 14. Alternatively, the sanding of
interior surface 106 may be sufficient to separate skirt portion 102 from
excess 107 at cut-line 200. Planar interior surface 106 provides
sufficient surface area for securing panel component 100 to surface S. As
noted above, the width of interior surface 106 of skirt portion 102 is
preferably between about 0.250 inches to about 0.375 inches after
separating excess portion 107 therefrom. Furthermore, interior surface
106 is sanded or machined to have an angular configuration relative to
panel portion 102, as best shown in FIGS. 14 and 15, to provide
tensioning force as described above. Preferably, interior surface 106 is
angled at from between about 5° to about 10°, similar to
the other embodiments.

[0080] It should be understood that the contoured portion may be formed to
have any configuration, pursuant to consumer preference, so long as it
does not extend below interior surface 60a (or 106) of skirt portion 54
(or 102). Therefore, contoured portions 56 is only an exemplary
configuration of the contoured portion for purposes of explanation.
Preferably, the interior surface 60 of contoured portion 56 has a portion
that is coplanar with skirt portion 54 (or 102) when the panel component
is secured to surface S, as best shown in FIG. 10.

[0081] A method of decorating a planar surface S includes the steps of
providing a planar surface S; providing a plant-on panel component 50, as
described above; and adhesively securing the plant-on decorative panel
component 50 so that the interior surface 60a of the skirt portion 54 is
flush with the planar surface S, thereby generating a tensioning force F
between the skirt portion 54 and the planar surface S. It should be
understood that the plant-on panel component 50 may be adhesively secured
to any planar surface S, such as a door face, wainscot, a furniture or
cabinet door, a wall, or the like. Additionally, panel component 50 may
be trimmed and/or sanded (depending on the particular embodiment) as
desired prior to securing same onto surface S. A planar surface S such as
a door face may be decorated with a door skin component 80, as described
above, in a like manner.

[0082] The present invention is also directed to a kit for decorating a
planar surface, such as a planar door face D, a wall, or the like. The
kit comprises at least a first reverse molded wood element E1, but may
include a plurality of reverse molded wood elements, E1, E2, E3 and E4,
as best shown in FIG. 16. Each one of elements E1-E4 comprises panel
portion 52 lying on a first plane, skirt portion 54, and contoured
portion 56, as described above.

[0083] Although the kit is described as having four elements E1-E4, it
should be understood that the kit may include any number of elements, as
desired by the consumer. Furthermore, each of the elements may have
either the sane shape and size dimensions, or the elements of the kit may
differ in size and shape in order to decorate a door, as best shown in
FIG. 16. Furthermore, the elements need not be rectangular, but may be
any desired shape, as explained above with respect to plant-on panel
component 50.

[0084] The kit may also include adhesive, such as double sided adhesive
tape, for securing each element E1-E4 to the planar surface (shown as
door face D in FIG. 16). Thus, the consumer may purchase the kit, and
secure the elements E1-E4 to a planar surface to create various panel
configurations. Note that skirt portions 54 of each of elements E1-E4 may
also be trimmed to an appropriate size, as explained above.

[0085] It will be apparent to one of ordinary skill in the art that
various modifications and variations can be made in construction and
configuration of the present invention, without departing from the scope
or spirit of the invention. It is intended that the present invention
cover all modifications and variations of the invention, provided they
come within the scope of the following claims and their equivalents.